BRIDGE DECK CONCRETE OVERLAYS

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1 BRIDGE DECK CONCRETE OVERLAYS Challenges and Inspection Doug Beer, PE March 6, 2018

2 Overview 1 2 Types of Overlays Selecting Overlay Type 3 Repair Prior to Overlay Surface Preparation Material Consistency Curing Challenges & Inspection 2

3 Types of Overlays Dense Concrete Overlay Reinforced Concrete Overlay Latex-Modified Concrete Overlay Multi-Layer Polymer Overlay 3

4 Overlay Selection Define Need 1. Restoring Skid Values 2. Sealing Cracks 3. Matching New Profile 4. Adding Structural Value 5. Chloride/Corrosion Protection 4

5 Overlay Selection Multi-Layer Epoxy Overlays Improving Skid Values and Crack Sealing Concrete Overlays Matching New Profiles, Structural Capacity, & Chloride/Corrosion Protection 5

6 Concrete Overlays Dense Concrete Overlays HPC Concrete with a Course Aggregate factor of at least 0.55, Class of Concrete CO Reinforced Concrete Overlays HPC Concrete with Fibers or Reinforcing Steel. Course Aggregate factor of at least 0.55, Class of Concrete CO Latex Modified Concrete Overlays 24.5 gals/cy of Latex and 18.9 gals/cy of Water (do not usually need that much water), 658 lb/cy of cement. Class of Concrete LMC 6

7 Materials Equipment Construction Measurement Payment 7

8 MATERIALS 8

9 EQUIPMENT 9

10 EQUIPMENT 10

11 EQUIPMENT 11

12 CONSTRUCTION 12

13 Item 421 Item

14 Material Controls As with all structural concrete, trial batches and mix consistency is key to a successful overlay. Several Trial batches may be needed to achieve the optimum mix design, this can get costly with the price of Latex. Work with suppliers and contractors for compensation or make subsidiary through General Notes. Specification recommends 1.0 : 2.8 : 1.7 weight ratio of cement-sand-coarse aggregate, with a coarse aggregate volume of 30% - 45% by weight of total aggregate. Work with contractor/supplier to minimize paste volume by decreasing sand content and increasing coarse aggregate. Good mix design practices should used when creating LMC mix design, less paste. Check with local Redi-Mix suppliers and try to get them to bid LMC Overlay projects. Steel Fibers can be added, approximately 40lbs/cy 14

15 Fresh Concrete with Steel Fibers 15

16 Volumetric Mixers have had success with LMC Overlays, but consistency is problematic. Performing good trial batches with Volumetric Mixers is difficult. Require the supplier with calibrated equipment and operator to perform the trial batches ahead of placement operations. If material properties change (moisture content) between time of trial batch and placement, perform additional concrete testing and equipment calibration before overlay operations commence. The specification does not limit LMC to volumetric mixers. Redi-Mix suppliers are hesitant with LMC, but it has been done successfully several times. Material consistency is greatly improved and performance enhanced. It should be encouraged to utilize these suppliers, but, additional chipping/cleaning of mixer drums should be anticipated and bid. 16

17 CONSTRUCTION REPAIR EXISTING CONCRETE BRIDGE DECK Preferred Repair Material CL S Concrete if Cure Time Permits HES for Accelerated Construction When Approved, Repair Concurrently with Overlay 17

18 Bridge Deck Repair Prior to Overlay 18

19 CONSTRUCTION SURFACE PREPARATION Item 483 Milling Hydro-Demolition Shot Blasting 19

20 CONSTRUCTION SURFACE PREPARATION Milling Hydro-Demolition Shot Blasting 20

21 CONSTRUCTION SURFACE PREPARATION Milling Hydro-Demolition Shot Blasting 21

22 Surface Preparation Surface Preparation Should Occur as Close as Possible Before Overlay Placement For Multiple Span Bridge, Specify Multiple Mobilizations of Surface Preparation Specify Additional Pressure Washing Prior to Overlay Sand-Blasting will be needed in areas that are inaccessible to Deck Surfacing Equipment, expansion joints, etc. 22

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24 Placing and Finishing Concrete Perform Dry-Run Inspection and Verify Overlay Thickness and Cleanliness Ensure Expansion Joints are formed so that overlay will not be in contact with the adjacent span. Moisten Surface to SSD Apply bonding grout as specified, do not allow bonding grout to dry prior to overlay placement. Vibrate overlay to ensure adequate consolidation in corners and angles and around exposed reinforcing steel. Use mechanical screeding device to strike off overlay and finish the surface to final grade Hand-finish edges and joints to ensure tight and uniform finish. 24

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26 Armor Joint Isolation Accomplished by: Placing backer rod to fill joints, then scoring before polymer gels or saw cutting after its fully cured NO! YES Overlay cracks and pulls away from the deck. Overlay moves along with the deck.

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28 Application of Bonding Grout 28

29 LMC with Bonding Grout and Expansion Joint Covered 29

30 Mechanical Screed with Pan Float and Burlap Drag 30

31 Hand Finish Edges and Forming at Armor Joint 31

32 Manual Screeding and Vibrators for Small Areas 32

33 Curing This is a critical step in bonded bridge deck overlay success. Due to the thin overlay and large surface area, plastic/drying shrinkage is problematic. Limited bleed water and rapid evaporation induce cracking, curling, and warping. This causes the edges of the overlay to de-bond and ultimately progress to interior and delaminate the overlay. Traffic vibrations can also prohibit good overlay bonding, if possible, detour traffic during the curing phase. HPC Concrete Overlays should be treated similar to typical bridge deck curing methods, however, the time of application of evaporation retardant, interim curing, and final curing should be monitored closely and applied as soon as possible. LMC Overlays should have curing placed immediately, missing this window will cause plastic shrinkage cracking. 33

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36 Curing Ensure an adequate quantity of wet burlap is available prior to placing concrete. Ensure adequate man-power is dedicated to the curing operation. Do not allow burlap to dry, continue to apply water until the plastic sheeting is placed. Contractor will need to monitor curing operation and add water as needed, at minimum, first 24 hours is critical to the overlay. 36

37 The Cure Blanket Toss 37

38 Burlap Blanket Station 38

39 LMC Issues The most widespread problem with LMC overlays is cracking. LMC has good bonding characteristics with proper surface preparation and cleaning. Application of finish water and curing water is counterintuitive of typical concrete bridge deck practices. Latex is approximately 50% styrene-butadiene and 50% water, the W/C ratio can be very low. This causes the system to have minimal water for hydration and therefore rapid loss of bleed water occurs. As soon at the LMC forms a skin, wet burlap should be applied. And water applied generously to the blankets, apply plastic sheeting ASAP and continue with application of water. Surface finish of LMC Overlays will be compromised by the quick application of burlap, but should not affect ride if original grading of the screed and forms are true. 39

40 LMC Issues Super-elevated cross-slopes and phased construction, will cause the LMC to creep downhill and could make construction joints rough, due to slump. Cross-slope should be considered when selecting LMC overlays. Phase/construction joints should not occur at wheel paths and may require grinding. The edges of the overlay where the screed rail was set will need to be filled in after overlay placement with similar concrete or TY D Standard repair material. 40

41 Surface Preparation Issues Hydro-demolition provides a very aggressive surface texture and will enhance mechanical bonding, less slipping and delamination. But, the concrete fines will be left in the valleys and need to pressure washed prior to placement of reinforcing or overlay. Shot-blasting provides a clean and bondable surface, but should be done within 48 hours(?) to ensure no contamination occurs. Recommend multiple mobilizations of the shot-blasting operation if several spans will be poured at different dates. Air Compressor Cleaning is desirable, leaf blowers will work but not as effective. Specify through General Notes additional pressure washing prior to overlay, psi recommended. Specification states water blasting, which can be open to contractor interpretation in the field. 41

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48 QUESTIONS? Doug Beer, P.E. Bridge Division Construction & Maintenance

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